Transcript 01_TIARA-2013-SOLEIL_MDx

TIARA Workshop on RF Power Generation
for Accelerators
DEVELOPMENTS
OF HIGH POWER
CW SSAs at
SOLEIL
Uppsala, June 17th - 19th, 2013
Massamba DIOP, R. LOPES, P. MARCHAND, F. RIBEIRO
OUTLINE
 SSA operation at SOLEIL
 BOOSTER 35 kW
 STORAGE RING 180 kW
 SOLEIL 352 MHz SSA State of the Art
 500 MHz SSA R&D and new projects
 LNLS : 2 x 45 kW (476 MHz)
 SESAME : 2 x 75 kW
 THOM-X : 50 kW
 R&D at other frequencies
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SOLEIL OVERVIEW
 S-Band (3 GHz) LINAC
 BOOSTER: 100 MeV => 2,75 GeV (3 Hz)
 2,75 GeV STORAGE RING (500 mA)
 Opened to users since 2007
26 beamlines funded: 18 with insertion devices and 8 with bending magnets
 2012: 22 beamlines opened to users
BOOSTER (BO) RF SYSTEM
 En : 100 MeV  2.75 GeV (rep. 3 Hz) ; Vcav : 100  900 kV @ 352 MHz
 1 x 5-cell Cu cavity (CERN LEP)  Ptot : 20 kW (Pdis : 15 kW, Pbeam : 5 kW)
 1 x solid state amplifier  35 kW CW @ 352 MHz (developed in house)
Cavity in the BO ring
BO RF room (amplifier & LLRF)
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35 kW SSA OF THE SOLEIL BOOSTER
 147 amplifier modules and power supplies on
8 water-cooled dissipaters
330 W amplifier module (VDMOS Transistor - Semelab D1029UK05)
600 W, 300 Vdc / 30 Vdc converter
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35 kW SSA POWER COMBINATION
19 W
192 W
24 W
240 W
30 W
64 x
330 W
2.5 kW
20 kW
x 2  40 kW
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DIAGRAM OF THE BO RF CONTROL SYSTEM
AMPLIFIER
Pref
An. & dig. I / O
CAVITY
AND LLRF
Water flows,
Temperatures, …
PC
SOLEIL
CONTROL
« TANGO »
PLC
Ethernet
CPCI
Power
supplies off
LLRF : Low Level RF Electronics
(amplitude, phase & frequency loops)
Vacuum
PSS
Machine
intlk
I x 2 x 147 modules
Pi, Pr x 16
MULTIPLEXING
AI
Cmd
Hardwired
fast interlock
µcontroller
RS232
Pin
Pout
to amplifier
RF switch
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OPERATIONAL EXPERIENCE WITH THE
BO RF SYSTEM
The Booster RF plant is in operation since mid 2005.
Up to date, after 7 years operation (> 44 000 running hours),
only a single trip in operation, due to a human mistake (2006)
The 35 kW solid state amplifier has proved to be very reliable.
Only 8 (out of 150) module failures: 5 bad solder quality and 3 broken transistors,
which did not affect at all the operating conditions
and could be quickly repaired during scheduled machine shutdowns.
 Advantage of the high modularity and redundancy
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STORAGE RING (SR) RF SYSTEM
 E = 2.75 GeV, E = 1.2 MeV, Ib = 500 mA
 PRF = 600 kW & VRF = 4 MV @ 352 MHz
 2 cryomodules (CM), each containing a pair of
single-cell s.c. cavities
 Each cavity is powered with a 180 kW solid state
amplifier
 Both CM supplied with LHe (4.2 K) from a single
cryo-plant
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SR 180 kW RF SYSTEM
Same principle as for the BO one, extended to 4 towers of 45 kW
 726 modules / amplifier x 4 cavities  16 towers & ~ 3000 modules
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COMPONENTS OF THE SR AMPLIFIER
600 W – 280 Vdc / 28Vdc converter
352 MHz - 315 W amplifier module
(LDMOS transitor - Polyfet LR301)
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COMPONENTS OF THE SR AMPLIFIER
Power splitters
2 , 8 and 10 ways
(90, 350 & 20 pcs,
respectively)
Power combiners
2.5, 25, 100, 200 kW;
320, 34, 26 & 6 pcs,
respectively
(S11 < - 30 dB)
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AMPLIFIERS 1 & 2 => 2 CAVITIES OF CM1
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DIAGRAM OF THE SR RF CONTROL SYSTEM
Water flows,
Temperatures, …
CAVITY
AND LLES
An. & dig. I / O
AMPLIFIER
AI
SOLEIL
CONTROL
« TANGO »
PLC
Cryo
PLC
Ethernet
PC
Pref
I x 2 x 680 modules
Pi, Pr x 80
MULTIPLEXING
Vacuum
PSS
Machine
intlk
Cmd
µcontroller
Hardwired
fast interlock
CPCI
RS232
Power
supplies off
Pin
Pout
to amplifier
RF switch
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AMPLIFIER CONTROL via the UCONTROLLER
Transistor Currents, Pi, Pr For A Tower
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STORAGE RING
OPERATIONAL EXPERIENCE
RF power amplifiers
- Proved to be very reliable : after > 38000 running hours over ~ 7 years,
only 5 short beam dead times  ~ 100 % operational availability, MTBF > 1 year
- Module failure rate of ~ 3.5 % per year  ~ no impact on the operation
 Matter of maintenance : 1 hour @ each shutdown for ~ 10 mod. change
 Yearly repair cost of ~ 5 k€ (for the four 200 kW amplifiers)
4%
Rate of module failures in SOLEIL SSA
Soldering preventive maintenance
Transistor Failure
3%
Soldering Failure
2%
1%
0%
2006-2007
2008
2009
Year
2010
2011
2012
Significant improvement expected from the new generation modules
with more robust transistors and less thermal stress
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SOLEIL RF STATUS
 After 7 years of operation, SSA innovative design has proved itself and demonstrated
that it is an attractive alternative to the vacuum tube amplifiers, featuring an
outstanding reliability and a MTBF ( > 1 year).
 Thanks to the acquired expertise and the arrival of the 6th generation LDMOS,
SOLEIL has carried out developments which led to doubling the power of the
elementary module (650 W) while improving the performance in terms of gain,
linearity, efficiency and thermal stress.
 Advantages of SSA technology: low phase noise, good linearity, high reliability,
long life time, easy maintenance, simple spare parts, no HV, no X ray.
=> UPGRADE to benefit from 6th generation improvements
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Why SSA upgrade at SOLEIL?
 Easier maintenance, better performances




Low gain and phase dispersion (+/-0,2dB and +/-5° instead of +/-1,5dB and +/-7,5°)
More power capability => optional operation with 2 or 3 amplifiers out of 4
More robust transistors
Transistor supply made easier (NXP, Freescale…)
 Cost savings
 6% increase in module efficiency => less modules => electrical power savings
=> compensation for upgrade costs within 4 years
 Old PCB re-used and only transistors are changed => less than 10% of the amplifier
cost
At the beginning, we thought about replacing only the damaged modules with
new transistors. But the very strong performance and cost advantages made
us change our strategy for a controlled and planned massive upgrade.
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SSA upgrade at SOLEIL in details
 Transistor LR301 replaced by BLF574XR
 Same footprint as LR301
 Up to 500W CW (high power margin) Gain & phase
 Better robustness and relialibity
compensation
Inner
circuit
Outer
circuit
 Add gain and phase compensation circuits
 Components change for matching
Comparison LR301 vs BLF574XR
RF parameters
LR301
BLF574XR
Advantages of BLF574XR
Gain
13,7
20
Less drivers (+0,5% for overall efficiency)
Efficiency
62%
68%
Better efficiency ( +4,5% for overall efficiency)
Output power
315W ( 350W tested)
330W (450W tested)
More Power Margin
Gain Dispersion
+/-0,8dB at Pnom
+/-0,2dB at Pnom
No sorting
Phase Dispersion
+/-7,5° at Pnom
+/-5° at Pnom
(+/-2,5° expected)
Better combining efficiency
 Test of 10 BLF574XR samples:
 Assembling and test of 2,5kW unit based on BLF574XR modules during 4000h on dummy load
 Mounting them in our amplifier (AMP1) since one year in operation without any problem
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SSA upgrade at SOLEIL in details
18
50
16
45
Gain Dispersion
12
10
8
6
4
35
30
25
20
15
2
10
0
5





Jan-Feb 2013: Supplying all components (RF capacitors, transistor, etc…)
March & April 2013 : Modifications and adjustments of 100 modules
May 2013 : Replacement of 90 drivers on two 180kW amplifiers
Oct 2013 : Replacement planned of 90 drivers on two last 180 kW amplifiers
Replacement of last stage modules ~ 4-8 years (1 or 2 tower per year)
169,3 °
169,0 °
168,4 °
170,2 °
Phase
167,8 °
167,4 °
167,1 °
166,8 °
166,5 °
166,2 °
165,9 °
165,6 °
165,3 °
165,0 °
164,6 °
164,2 °
162,7 °
163,8 °
21.18 dB
21.08 dB
21.13 dB
21.03 dB
0
21.25 dB
Gain
Phase Dispersion
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Number of modules
14
19.20 dB
19.33 dB
19.43 dB
19.48 dB
19.57 dB
19.66 dB
19.85 dB
19.92 dB
19.98 dB
20.03 dB
20.10 dB
20.15 dB
20.80 dB
20.90 dB
20.97 dB
Number of modules
Distribution of 100 first BLF574XR modules
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SOLEIL 352 MHz SSA STATE OF THE ART
6th generation transistors (Vdc = 50 V) + SOLEIL expertise  fast progress
 At 352 MHz, Pmod ~ 700 W, G > 20 dB,  > 70%
[ Current LR301 mod. (Vdc = 28 V) : P = 315 W, G = 13 dB,  = 62 % @ 352 MHz ]
 Huge improvement : Pmod x 2.2 , better performance (G ,  , linearity)
& thermal stress strongly reduced (ΔT : - 60 °C)  longer lifetime
 Beg. 2009, transfer of technology agreement concluded with ELTA-AREVA
 ESRF contract for 7 SOLEIL type amplifiers of 150 kW (14 x 75 kW towers)
 June 2010 : A 10 kW unit (16 modules) successfully tested at SOLEIL
 June 2011 : Commissioning of the first 75 kW tower at ESRF
 March 2012 : Commissioning of the 4 x 150 kW amplifiers for the booster,
which, up to now, have run quite satisfactorily for 1.5 year
 2013 – 2014 : Delivery of the 3 amplifiers for the SR, slightly modified as
compared to the Booster for handling high CW VSWR ( Jorn Jacob)
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SOLEIL 352 MHz SSA STATE OF THE ART
Transistor
type
Power supply
per module
Module Parameters
at nominal conditions
Amplifier design
& nominal power
VSWR limitation *
Comments
SOLEIL
Booster
D1029UK05 
SEMELAB
1 x 600 W
280/28 Vdc
P1dB = 330 W, G = 11 dB
 = 60 % , Tmax = 130°C
No limit with SOLEIL
Booster duty cycle
1 trip over 7 years due
to a human mistake
SOLEIL SR
(actual)
SOLEIL SR
(upgrade)
LR301
Polyfet
BLF574XR
NXP
1 x 600 W
280/28 Vdc
70 kW full reflection
Pr = 35 kW @ 180 kW
70 kW full reflection
Pr = 32 kW @ 200 kW
MTBF > 1 year
1 x 600 W ♯
280/48 Vdc
P1dB = 315 W, G = 13 dB
 = 62 % , Tmax = 130°C
P1dB = 350 W, G = 22 dB
 = 69 % , Tmax = 90°C
1 tower of 8 dis
Pnom = 35 kW
modulated
4 towers of 10 dis
Pnom = 180 kW cw
4 towers of 10 dis
Pnom = 200 kW cw
ESRF
Booster
(800W load)
ESRF SR V2
(1.2kW load)
BLF578
NXP
2 x 600 W
280/48 Vdc
P1dB = 650 W, G = 20 dB
 = 71 % , Tmax << 75°C
=
=
=
ESRF SR V3
(power
circul)
=
=
=
•
•
•
•
2 towers of 8 dis
Pnom =150 kW
modulated
2 towers of 8 dis
Pnom = 150 kW cw
 Pnom = 140 kW
No limit with ESRF
Booster duty cycle
85 kW full reflection
Pr = 50 kW @ 150 kW
140 kW CW full
reflection
Much more robust
than LR301
In CW Pr limited at 5
kW
for Pi = 150 kW
 modified
combination
 + 1.2 kW load
+ 5% power loss
- 3% on efficiency
Extra costs
* VSWR limitation: when operating the amplifier at high CW incident power, Pi, with a high VSWR and the worst phase condition, an
unpowered module (ie, both of its power supplies, or both sides of its push-pull broken) can see a power on its circulator load, Pload > Pi
Rem: full reflection for a short time (~10 ms) is not a problem ( Pr interlock)
♯
2 PS in series on 2 modules in //
 VDMOS
; all the other cases are LDMOS
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500 MHz R&D ON SSA
6th generation LDMOS  BLF578 : 650 W modules
RF characteristics:







RF Output Power: 650 W CW at 1 dB
Gain : 17dB
Efficiency: > 60% at Pn
Gain dispersion : +/- 0.2 dB at Pn
Phase dispersion :+/- 5° at Pn
Input Return Loss : < - 40 dB at Pn
Unconditional stability (K>10 dB)
High efficiency (96%) 230 V_ac / 50 V_dc power converters
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500 MHz R&D ON SSA
10 kW unit prototype for long term test (> 500 hours)
Efficiency ~ 55%
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500 MHz R&D ON SSA
Power combination components
2 x 80 kW
2-way splitter
2 x 40 kW
8-way splitter
8 x 5 kW
8 x 650 W
Pi - Pr monitoring coupler
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WAVEGUIDE-to-COAXIAL
COMBINER (WaCCo)
2 coaxial inputs
dl
WG
output
 Two 6 inches coaxial input ports (2 x 80 kW)  1 WG output
 Replace a coaxial combiner + a coaxial-to-WG transition
 Design optimization with HFSS and Microwave Studio
 A 500 MHz prototype has been validated at signal level
 Movable SC  can ensure a good matching for different configurations with
diff nb of dissipaters per tower or diff nb of modules per dissipater
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SOLEIL R&D ON SSA
 Collaboration agreements
 LNLS (Brazilian LS) : 2 x 45 kW @ 476 MHz, in operation
 SESAME (LS in Jordan) : 4 x 150 kW @ 500MHz
 THOM-X (Compact source of hard rays): 50 kW @ 500MHz
 R&D at other frequencies
 FM band (88 – 108 MHz)  1 kW module with G > 25 dB and  ~ 80 %
 L band (1.3 & 1.5 GHz) for 4th generation LS  Pmod > 400 W
o LUNEX5 : 20kW @ 1.3 GHz – R&D for the TDR
The SSA technology is ideally suited to the ERL requirement, which is
typically of a few tens of kW at 1.3 – 1.5 GHz.
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SOLEIL-LNLS COLLABORATON
Two amplifiers of 50 kW @ 476 MHz for the LNLS storage ring with
components designed by SOLEIL (400 W RF modules with BLF574)
April 2010 : the SOLEIL - LNLS team in Campinas-Brazil,
after successful tests of the amplifiers
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LNLS 50 kW RF PLANTS
The two 50 kW SSA have run satisfactorily on the LNLS SR for ~ 3 years
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THOM-X 500 MHz 50 kW AMPLIFIER
(PRELIMINARY DESIGN)
Cabinet Design
Tower Design
AC-DC Power Supplies
2m
16 Amplifiers per Dissipator
2m
High Power Combination
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2m
2m
PROPOSAL FOR THOM-X AMPLIFIER
CONTROL SYSTEM
6 MUX Esclaves
RS-485
Ethernet
MUX
Maitre
MUX D1
MUX D2
MUX D3
MUX D4
MUX D5
MUX D6
µC
µC
µC
µC
µC
µC
16 modules
16 modules
16 modules
16 modules
16 modules
16 modules
4 préampli
PC local
supervision
TANGO
MUX D numérique
Multiplexeur
I/O
RS485
µC
I/O
ADC
ADC
ADC
ADC
ADC
ADC
adresse
Multiplexeur
(1 par dissipateur de 16 modules)
Comparateurs
Bus RS-485
8 x (2 courants + 1 temp. )
½ dissipateur haut
P_incidente
P_réfléchie
P_incidente
P_réfléchie
½ dissip. haut
(8 mod.)
½ dissip. bas
(8 mod.)
8 x (2 courants + 1 temp.)
½ dissipateur bas
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SESAME 500MHz 140kW AMPLIFIER
(PRELIMINARY DESIGN)
 AC-DC Power Supplies
(160 x 2kW modules)
1 Waveguide Combiner
(WaCCo)
2m
 2 x 75 kW RF combination
 64 8-way splitters
 16 dissipators
 256 amplifier modules
3m
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SUMMARY & CONCLUSIONS
 BOOSTER 35 kW SSA (D1029UK05)
 STORAGE RING 180 kW SSA (LR301)
 Operation and upgrade to 6th generation BLF574XR
 SOLEIL 352 MHz SSA State of the Art
 Pmod ~ 700 W, G > 20 dB,  > 70%
 500 MHz SSA R&D (BLF578)
 Pmod ~ 650 W, G ~ 17 dB,  > 60%
 500 MHz SSA based projects
 LNLS : 2 x 45 kW (476 MHz)
 SESAME : 2 x 75 kW
 THOM-X : 50 kW
 R&D at other frequencies
 FM band (88 – 108 MHz)  1 kW module with G > 25 dB and  ~ 80 %
 L band (1.3 & 1.5 GHz) for 4th generation LS  Pmod > 400 W
o LUNEX5 : 20kW @ 1.3 GHz
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Thank you for your attention
34